In order picking, there are various ergonomic aids that significantly reduce the physical strain on employees. These include vacuum lifters, electric pallet trucks, mobile lifters, and pulling aids. Which aid is most suitable depends on the type of load, its weight, the frequency of the task, and the layout of the warehouse. In this article, we answer the most frequently asked questions about ergonomic order picking, ranging from the most physically demanding tasks to choosing the right aid.
Which tasks in order picking place the greatest physical strain on workers?
The most physically demanding aspect of order picking involves manually lifting, carrying, and setting down boxes, bags, or pallets, especially when done at low or high heights. Repetitive bending, twisting the torso, and pushing or pulling heavy loads are the main causes of back pain and musculoskeletal disorders among warehouse workers.
Specifically, the following actions pose the greatest risk:
- Picking up boxes or bags from the floor or from a low position
- Placing loads at or above shoulder height
- Repeatedly twisting while holding a heavy load
- Traveling long distances with a full pallet or roll container
- Manual stacking and unstacking of pallets
The more frequently these tasks are performed and the heavier the load, the greater the cumulative effect on the body. In busy warehouses where employees make hundreds of picks per day, the risk of overexertion increases rapidly. Ergonomic aids for order picking are therefore not a luxury, but a necessity.
Which ergonomic aids are most commonly used in order picking?
The most commonly used ergonomic aids in order picking are vacuum lifters, electric pallet trucks, mobile lifters, and pulling aids. They are designed to make it easier to lift, carry, and move loads, thereby systematically reducing the physical strain on warehouse workers.
An overview of the most commonly used order-picking tools:
- Vacuum lifters: for quickly and safely lifting boxes, bags, or sheets without manual effort
- Electric pallet trucks: for moving full pallets with minimal effort
- Mobile lifts: for raising loads to the correct working height
- Pulling aids and electric pullers: for pushing and pulling heavy roll containers or carts
- Pallet Handlers: for automatically rotating or changing pallets
The choice depends heavily on the type of load and the specific operation. For a comprehensive overview of applications by product type, please visit the applications page.
How does a vacuum lifter help with order picking of boxes and bags?
A vacuum lift assists with order picking of boxes and bags by gripping the load using negative pressure and effortlessly moving it or raising it to the desired height. The employee no longer has to lift the load manually, which significantly reduces back strain, shoulder pain, and fatigue, even at high picking frequencies.
A vacuum lifter is particularly effective for handling boxes and bags because:
- The load is picked up and placed in one smooth motion
- No physical grip is required, which relieves strain on the wrists and fingers
- The working height can be easily adjusted to the position on the rack
- Both light and heavy loads can be handled without extra effort
Vacuum lifters are available in versions that are mounted on a fixed arm, a rail, or a mobile frame, depending on the layout of the picking process. This makes them suitable for use in both fixed workstations and dynamic environments.
What is the difference between a manual and an electric pallet truck for order picking?
The main difference is that a manual pallet truck is pushed and pulled by the employee using their own muscle power, while an electric pallet truck automatically handles the movement and, in some cases, the lifting as well. During intensive use or over longer distances, an electric pallet truck significantly reduces physical strain.
When choosing between the two options, these factors come into play:
- Driving distance: For shorter distances, a manual truck is sufficient; for longer distances, an electric model is more ergonomic
- Load weight: Heavier pallets require more physical strength when using a manual pallet truck
- Frequency: With multiple trips per hour, the workload quickly adds up when using a manual forklift
- Floor surface: On uneven or slightly sloped floors, electric assistance is a safety benefit
For warehouses with intensive pallet handling, an electric pallet truck is usually the most ergonomically sound choice. View the full selection on the pallet trucks page.
When is a semi-automatic solution better than a standalone tool?
A semi-automatic solution is better than a standalone assistive device when the same action is repeated very frequently, when multiple employees perform the same task, or when the physical strain remains too high despite the use of a manual assistive device. Semi-automation systematically takes over repetitive actions rather than merely alleviating them.
Specific situations in which semi-automation offers added value:
- Continuously swapping or rotating pallets during a picking process
- High volumes where manual tools limit the speed of the process
- Workstations where employees repeat the same strenuous task all day long
- Workplaces where employee turnover or absenteeism due to physical strain is high
A standalone device, such as a vacuum lift or mobile lifter, remains the right choice for variable tasks or smaller volumes. Semi-automation is an investment that pays for itself with high, predictable work volumes. The deciding factor is not a fixed number of picks, but whether the operation is consistent enough to justify an integrated solution.
How do you choose the right ergonomic aid for your picking process?
You should choose the right ergonomic aid for order picking based on four criteria: the type of load (box, bag, pallet, drum), the weight, the frequency of the task, and the physical location in the warehouse. An aid that is perfectly suited to one situation may be completely unsuitable for another.
Follow these steps to make the right choice:
- Identify the strenuous task: what is being lifted, how heavy is it, and how often?
- Analyze the working height: Is the work being done at floor level, at waist height, or above shoulder height?
- Assess the available space: Is there enough room for a rail, an arm, or a mobile device?
- Consider the user: What level of operation is feasible for the employees?
- Test it before you decide: a tool that doesn't work well in practice won't be used
A thorough job analysis is the most reliable way to make the right choice. This will help you avoid investing in a tool that sounds good on paper but doesn’t work out in practice.
How Logitrans Handling Helps with Ergonomic Order Picking
We guide companies through the entire process—from start to finish—to improve the ergonomics of their picking process. Whether it involves a single task or an entire warehouse process, we analyze the situation and propose a concrete solution that benefits both the employee and the business process.
What we offer specifically:
- Free workplace analysis: A specialist assesses physically demanding tasks in the workplace and proposes targeted solutions
- Wide range of products: from vacuum lifters and hoists to electric pallet trucks and semi-automatic systems
- Demonstration Room in Drongen: You can test the assistive devices with your own materials before making a decision
- Training and installation: We ensure that employees use the device correctly and safely
- Maintenance Contracts: Through our service department, we keep your equipment in top condition
Would you like to know which ergonomic aid is best suited to your picking process? Contact our specialists for a no-obligation consultation or a free workstation analysis.
Related Articles
- Why do boxes get damaged during order picking?
- How can I protect my employees from back injuries in the workplace?
- How often should a lifting aid be maintained, and how much does it cost?
- What is the difference between a mobile lift and a fixed lifting system?
- Does a lifting aid break down quickly with intensive daily use?
